POWER REGENERATION CONVERTER INSTRUCTION MANUAL
Thank you for choosing the Mitsubishi Transistorized inverter option unit. This instruction manual gives handling information and precautions for use of this equipment. Incorrect handling might cause an unexpected fault. Before using the inverter, please read this manual carefully to use the equipment to its optimum. Please forward this manual to the end user. This section is specifically about safety matters Do not attempt to install, operate, maintain or inspect the inverter until you have read through this instruction manual and appended documents carefully and can use the equipment correctly. Do not use the inverter until you have a full knowledge of the equipment, safety information and instructions. In this manual, the safety instruction levels are classified into "WARNING" and "CAUTION". WARNING CAUTION Assumes that incorrect handling may cause hazardous conditions, resulting in death or severe injury. Assumes that incorrect handling may cause hazardous conditions, resulting in medium or slight injury, or may cause physical damage only. Note that even the CAUTION level may lead to a serious consequence according to conditions. Please follow the instructions of both levels because they are important to personnel safety. A - 1
SAFETY INSTRUCTIONS 1. Electric Shock Prevention WARNING! While power is on or when the inverter is running, do not open the front cover. You may get an electric shock.! Do not run the inverter option with the front cover removed. Otherwise, you may access the exposed high-voltage terminals or the charging part of the circuitry and get an electric shock.! Before starting wiring or inspection, switch power off, wait for more than 10 minutes, and check for residual voltage with a meter (refer to chapter 4 for further details) etc.! Earth the 200V class regenerative converter unit in a class D or higher protective grounding method, and the 400V class in a class C or higher method.! Any person who is involved in the wiring or inspection of this equipment should be fully competent to do the work.! Always install the inverter option before wiring. Otherwise, you may get an electric shock or be injured.! Operate the switches and potentiometers with dry hands to prevent an electric shock.! Do not subject the cables to scratches, excessive stress, heavy loads or pinching. Otherwise, you may get an electric shock. 2. Fire Prevention CAUTION! Mount the regenerative converter unit to incombustible material. Mounting it directly to or near combustible material can cause a fire.! Do not connect a resistor directly to the DC terminals P/+, N/-. This could cause a fire. A - 2
3. Injury Prevention CAUTION! Apply only the voltage specified in the instruction manual to each terminal to prevent damage etc.! Ensure that the cables are connected to the correct terminals. Otherwise, damage etc. may occur.! Always make sure that polarity is correct to prevent damage etc.! While power is on or for some time after power-off, do not touch the power regeneration converter as it is hot. Doing so can cause you to get burnt. 4. Additional instructions Also note the following points to prevent an accidental failure, injury, electric shock, etc. (1) Transportation and installation CAUTION! When carrying products, use correct lifting gear to prevent injury.! Do not stack the inverter boxes higher than the number recommended.! Ensure that installation position and material can withstand the weight of the inverter option. Install according to the information in the Instruction Manual.! Do not install or operate the regenerative converter unit if it is damaged or any of its parts are missing.! Do not hold the inverter option by the front cover or operation panel; it may fall off.! Do not stand or rest heavy objects on the inverter option.! Check the inverter option mounting orientation is correct.! Prevent screws, wire fragments or other conductive bodies or oil or other flammable substance from entering the regenerative converter unit.! The regenerative converter unit is precision equipment. Do not drop it or subject it to impact.! Use the inverter option under the following environmental conditions: Ambient -10 C to +50 C (non-freezing) temperature Ambient humidity 90%RH or less (non-condensing) Storage -20 C to +65 C * temperature Indoors (free from corrosive gas, flammable gas, oil mist, dust Ambience and dirt) Maximum 1000m above sea level for standard operation. After Altitude, vibration that derate by 3% for every extra 500m up to 2500m (91%). 5.9m/s 2 or less (conforming to JIS C 0040) *Temperatures applicable for a short time, e.g. in transit. Environment A - 3
(2) Operation! Do not modify the equipment. WARNING (3) Maintenance, inspection and parts replacement CAUTION! Do not perform a megger test (insulation resistance measurement) on the control circuit of the regenerative converter unit. (4) Disposing of the inverter option! Treat as industrial waste. (5) General instructions CAUTION Many of the diagrams and drawings in this instruction manual show the inverter option without a cover, or partially open. Never operate the inverter option like this. Always replace the cover and follow this instruction manual when operating the inverter option. A - 4
CONTENTS EXPLANATION OF HANDLING... 1 1. Construction... 2 1-1 External view and name of each part... 2 2. Unpacking... 3 3. Installation... 4 3-1 Transportation... 4 3-2 Installation place... 4 3-3 Installation direction and spacing... 4 3-4 When the heat sink is placed outside the containing box... 5 4. Wiring... 6 4-1 Main circuit... 7 4-2 Control circuit... 11 5. Operation... 12 5-1 Inspection before operation... 12 5-2 Setting before operation... 12 5-3 Example of operation <In the case where acceleration and constant speed operation are driving mode and deceleration operation is regeneration mode>... 13 6. Maintenance and Inspection... 14 6-1 Suggestions for maintenance and inspection... 14 6-2 Inspection items... 14 7. Problems and countermeasures... 15 7-1 Inspection according to the alarm indicator... 15 7-2 Problem phenomena and their countermeasures... 15 8. Specifications... 16 8-1 Block diagram... 16 8-2 Explanation of the terminals... 17 8-3 Layout of terminals... 17 8-4 Outline dimensions... 18 8-5 Standard specifications... 20 8-6 Selection of peripheral devices... 21 8-7 Selection guide... 21
EXPLANATION OF HANDLlNG EXPLANATION OF HANDLING Incorrect handling might cause the inverter option to operate improperly, its life to be reduced considerably, or at the worst, the inverter option to be damaged. Handle the inverter option properly in accordance with the information in each section as well as the precautions and instructions of this manual to use it correctly. Power source Power source specifications Use the power supply within the permissible power supply specifications of the regenerative converter unit (page 20). No-fuse breaker (NFB) Installation of the no-fuse breaker (NFB)... see page 6 Install the NFB to connect it with both the inverter/servo and regenerative converter unit. Magnetic contactor (MC) Line noise filter (FR-BLF) Radio noise filter (FR-BIF) AC reactor for power-factor improvement (FR-BAL) Installation of the reactor... see page 10 For power coordination, always install an AC reactor for power-factor improvement. A wrong connection can disable the capabilities or cause the regenerative converter unit to be damaged. Installation... see page 4 Since environmental temperature has a significant effect on the converter life span, please decrease the temperature as low as possible so that it is not beyond the allowed temperature. DC reactor for power-factor improvement (FR-BEL) Regenerative converter unit Wiring... see page 7 Wrong wiring of the main circuit will cause the inverter to fail. Please keep the wires for control signals as far from the main circuit wiring so they do not suffer from noise effects. Inverter, Servo Line noise filter (FR-BLF) Setting... see page 12 If a suitable converter for an operated motor is not used, good braking performance is not obtained or overheat of the motor is caused. Before its operation, set the motor capacity by using the setting dial. To motor 1
1. Construction 1. Construction 1-1 External view and name of each part Fixture (two at the top and the bottom, removable) Rating name plate Indicator panel window Front cover Fixing screw for the cover Fig. 1 External view of the converter Detail of the indicator panel Indication of charging capacitor circuit Indication of a power source CHARGE POWER SW1 Setting dial for motor capacity REG 0% 50% 100% 150% (green) (green) (green) (green) (red) (red) (red) Indication of an alarm Light on at operation of protection function ALARM OCT UVT FIN NGV ERR Indication of regenerated power or alarm indication Indicated regenerative power (%). The power is given by a percentage of the motor capacity set by the setting dial. Also lit (flickers) when the protective function (OCT, UVT, FIN) is activated. 2
2. Unpacking 2. Unpacking After unpacking, please make sure of the following. (1) Check the rating plate on the power regeneration converter to make sure that this converter is the type you ordered. (2) Please make sure that there is no damage due to the transportation. If you have any questions or the converter has a damage, please contact to either the purchasing shop, our company branch or the nearest Mitsubishi sales representative. Meaning of symbols FR RC K Symbol Power source voltage Symbol Applicable motor capacity Nothing H 200V class 400V class 15 30 55 Indicating the maximum applicable motor capacity (kw) for 150% braking torque. Applicable motor capacity depends on the braking capacity and %ED. (see page 21) 3
3. Installation 3. Installation 3-1 Transportation Since the power regeneration converter generates heat, leave adequate clearances around it to dissipate heat. 3-2 Installation place (1) Do not install the converter in the following places: A place directly exposed to the sunlight. A hot and humid place. A place where oil mist, cotton dust, and dust are floating. A place sprinkled with water, oil, and polishing liquid. A place sprinkled with iron powder. A place exposed to a corrosive gas. A place exposed to inflammable gas. A place where vibration is applied. (2) When the power regeneration converter is contained in an enclosed box, make sure that generation of its own heat is fully considered to determine the cooling system and box dimensions. It is very important to check that not only the ambient temperature of the power regeneration converter but also that of the inverter contained together in the same box fall within their permissible ranges. (3) When the unit is used in a containing box for continuous regenerative operation, it is recommended to install it in the method given in Section 3-4. 3-3 Installation direction and spacing (1) Vertically attach the converter on a flat base without any step so that the letter "" on the name plate is visible from the front and tightly fix it by bolts. (2) Since the power regeneration converter generates heat, leave sufficient space around it to dissipate heat. Wire duct more than 10cm Space more than 5cm more than 5cm more than 10cm Leave clearances (more than 10cm) so that wire ducts will not obstruct cooling air. Space Cooling air Originally attached cooling fan Room for the converter Wire duct Suggestion of environmental temperature The life span of the converter greatly depends on the environmental temperature. Please make sure that the temperature at the positions indicated in the figure at the right side are not beyond the allowed ambient temperature (50 C). 5cm Measurement position 5cm 5cm 4
3-4 When the heat sink is placed outside the containing box The power regeneration converter generates more heat in applications where a regenerative status lasts long, e.g. winding or long-time, negative-torque lifting operation. If the unit is used in a containing box to perform such operation, the temperature in the box will rise significantly. To prevent this, it is recommended to place the heat sink of the power regeneration converter outside the box as shown in Fig. 3. The power regeneration converter is compatible with this mounting method by changing the setting position of its fixtures. Preparation Panel cutout of the enclosure...see page 19 for size of the hole Changing position of fixtures (two for upper and lower sides)... see Fig. 4 Inside of the enclosure Fixture Containing box Outside of the enclosure Setting position of a fixture on the converter when shipped from the manufacturer Regenerative converter unit Heat sink Cooling fan Fixture Fig. 3 Fixing method of heat sink outside the enclosure Fig. 4 Exchange of fixtures 5
4. Wiring 4. Wiring Suggestions for wiring (1) Connect the terminals P/+ and N/- with the inverter/servo terminals P and N correctly. If the connection is wrong, the power regeneration converter will display an alarm and will not operate properly. P/+ P Inverter, Servo P/+ P Inverter, Servo N N/- N/- N [Correct connection] [Wrong connection] (2) Always connect the FR-BAL AC reactor for power-factor improvement on the power source side of the inverter. (see page 7) (3) The wiring distance from the inverter/servo terminals P and N should be within 5m. Please use the wire of which the cross section is larger than the recommended one (see page 21). (4) The controlling circuit terminals common 5, SD, and SE are insulated between each other. Do not ground them. (5) A shielded wire or a twisted wire must be used for the connecting wire to the controlling circuit. It must be away from the main circuit (High voltage circuit, 200V sequence circuit etc.). (6) Pay attention not to fall cutting pieces of the wires into inside of the converter during work of wiring. Please work covering the ventilating hole of the converter. (7) Securely ground using the grounding terminal. Check list for design of wiring (1) Install the NFB and MC so that the power regeneration converter and the inverter or servo may be powered on/off at the same time. Power source NFB MC FR-BAL Inverter, Servo Power source NFB MC Inverter, Servo NFB MC [Correct connection] [Wrong connection] (2) Do not apply a voltage to the RES terminal of the controlling circuit. (3) Do not apply a voltage to the alarm output terminals A, B, and C without a load (relay coil, lamp etc.). (4) Since the input signals to the control circuit are on a low level, use two parallel micro signal contacts or a twin contact for contact inputs to prevent a contact fault. 6
4-1 Main circuit (1) Connection of the power source and the inverter or servo Regenerative converter unit lnput terminals of AC power source R/L1 S/L2 T/L3 N/- P/+ Inverter, Servo (Note 1) P N U V W Motor IM AC reactor for power-factor improvement (FR-BAL) (Note 3) Magnetic contactor (MC) No-fuse breaker (NFB) Magnetic contactor (MC) (Note 2) R S T Grounding Note 1: When using the 7.5K inverter and, always remove the brake resistor wiring. (For the FR-A500 series, remove the jumper across terminals PR-PX.) Note 2: If power is not applied to the inverter (the electromagnetic contactor is not ON), the RDY (ready output) signal of the power regeneration converter is not output. Always apply power to the inverter. Note 3: For power coordination, always install the FR-BAL AC reactor for power-factor improvement (option). (Refer to page 9 to select the FR-BAL.) Power source (2) In the case where the controlling circuit is connected to another power source When a protection circuit operates and the MC of the power source is switched off, power is not supplied to the controlling circuit. So, an alarm signal (relay) and an alarm indication cannot be maintained. If their maintenance is required, please provide another power source or connect the controlling circuit input R1/L11- R/L1 and S1/L12-S/L2 to the primary side of the MC. R1/L11 S1/L12 R/L1 S/L2 T/L3 AC reactor for power-factor improvement (FR-BAL) MC Power source 7
(3) To prevent overcurrent due to distortion If a current of about 180% of the rated current flows in the power regeneration converter, the distortion of the voltage waveform may increase, activating the overcurrent protection (OCT). Remove the jumpers across the phase detection terminals R-RX, S-SX, T-TX of the power regeneration converter, and wire the phase detection terminals RX, SX, TX to the primary side (power supply line) of the power factor improving reactor (FR-BAL). Keep the phase detection terminals R, S, T open. Power source No-fuse breaker (NFB) R S T When using the power source for the control circuit directly Magnetic contactor (MC) AC reactor for power-factor improvement (FR-BAL) R1 S1 Inverter, Servo R/L1 S/L2 T/L3 IM P N (Note) (Note) (Note) RRX S SX T TX R/L1S/L2T/L3 N/- P/+ Phase detection terminals Do not input main circuit power. Power regeneration converter () Note: When not using the phase detection terminals, fit jumpers across R-RX, S-SX, T-TX. The will not operate if the jumpers are removed. 8
(4) Connecting multiple units in parallel Power source AC reactor for power-factor improvement (FR-BAL) Inverter, Servo R S T U V W Motor IM P N Grounding P/+ N/- R/L1 S/L2 T/L3 AC reactor for power-factor improvement (FR-BAL) R S T Inverter, Servo U V W Motor IM P N Grounding P/+ N/- R/L1 S/L2 T/L3 [Correct connection] Power source Inverter, Servo R S T P U V W N Motor IM Grounding P/+ N/- R/L1 S/L2 T/L3 Inverter, Servo R S T P N U V W Motor IM Grounding P/+ N/- R/L1 S/L2 T/L3 [Wrong connection] 9
(5) In the case of connecting an AC reactor for power-factor improvement (FR-BAL (option)) (The FR-BAL must be connected for power coordination.) When using the power regeneration converter, always install the power factor improving AC reactor (FR-BAL) for power coordination. Connect it to both the inverter and power regeneration converter and install it on the power supply side of these units. Inverter Inverter NFB FR-BAL NFB FR-BAL Power source R S T Power source R S T R/L1 S/L2 T/L3 R/L1 S/L2 T/L3 [Correct connection] [Wrong connection] Selection of the reactor for power-factor improvement (FR-BAL) When applying the AC reactor for power-factor improvement to the power regeneration converter, make selection in accordance with the following selection table. Note that the reactor for area A should be selected if the power source equipment capacity is more than 100kVA and the wiring length is within 100m. Power regeneration converter type For other than area A Applicable AC reactor For area A -15K FR-BAL-22K FR-BAL-15K -30K FR-BAL-37K FR-BAL-30K -55K FR-BAL-55K FR-BAL-55K -H15K FR-BAL-H22K FR-BAL-H15K Power source equipment capacity 100kVA -H30K FR-BAL-H37K FR-BAL-H37K 0 -H55K FR-BAL-H55K FR-BAL-H55K 100m Wiring length Stipulation chart by power source equipment capacity vs. wiring length When using the power regeneration converter, select the AC reactor for power-factor improvement to meet the capacity of the power regeneration converter. (It does not depend on the inverter capacity, motor capacity and the number of units operated in parallel.) (6) In the case of connecting a DC reactor for power-factor improvement FR-BEL (option) Always connect the power regeneration converter terminal P/+ to the inverter terminal P. Area A N/- P/+ N/- P/+ Inverter Inverter N P P1 N P P1 FR-BEL [Correct connection] FR-BEL [Wrong connection] 10
4-2 Control circuit (1) Input signal (2) Output signal A B C RDY SE RES SD A B C RDY SE RES SD Reset Output of alarm (1 contact output) Output of stand-by (Note) (open collector output) Note: When the voltages across P-N of the inverter and power regeneration converter are both equal to or more than the specified value, the output of the stand-by signal causes the open collector output transistor to turn ON (conduct) 1 second after the condition has held. Suggestions for connecting the converter to a PLC When the converter is connected to a P.L.C.'s output unit (open collector output) and the controlling power voltage inside the is higher than the external power voltage of the P.L.C., a current flows in the as a command signal even if a transistor is not turned on as shown by a dotted line in the figure below. Countermeasures (1) Insert a diode for prevention of the reverse current. (2) Use independent type of output units for all terminals. (Example AY40A, etc.) (3) Make the external power source higher than the regenerative converter unit control power source. 12/24VDC Diode for countermeasure Photo coupler Y00 0V External power source RES SD Photo coupler Controlling power source (+24V) P.L.C. 11
5. Operation 5. Operation 5-1 Inspection before operation After finishing the installation and the wiring, please inspect the following items before switching the power source on. (1) Mistakes in wiring. Especially, connection of the main circuit terminals P/+ and N/-. (2) A short circuit made by the cutting pieces of wire etc. (3) Loosening of a terminal screw. Insulation resistance test. Do not carry out a insulation resistance test of the power source power regeneration converter. (see P.14) 5-2 Setting before operation Do not forget to adjust the setting dial of the motor capacity on the printed circuit board to the capacity of the motor to be operated. If the adjustment is not correct, the rated ability of the regenerative is not obtained or overheat of the motor is caused. Table 1 Dial figure and motor capacity Dial figure to set motor capacity Type 1 2 3 4 5 6 SW1-15K 7.5kW 11kW 15kW 18.5kW 22kW 200V 400V -30K 15kW 18.5kW 22kW 30kW 37kW 45kW -55K 30kW 37kW 45kW 55kW -H15K 7.5kW 11kW 15kW 18.5kW 22kW -H30K 15kW 18.5kW 22kW 30kW 37kW 45kW -H55K 30kW 37kW 45kW 55kW Setting dial for motor capacity Note: The value marked by a double circle indicates the capacity set at the time of shipping. 12
5-3 Example of operation <In the case where acceleration and constant speed operation are driving mode and deceleration operation is regeneration mode> Preparation The start signal of the inverter is turned off. The frequency (rate) command signal of the inverter is adjusted to zero. If a potentiometer is used, turn it fully to counterclockwise. Switch the power source on Switch NFB and MC on The power lamp and the charge lamp on the indicator panel are lit Start the inverter Switch the start signal of the inverter on Acceleration Constant rate Slowly turn the frequency setter fully cloockwise The rotation rate of the motor increases to become constant Deceleration Switch the start signal off The rotation rate of the motor decreases to a stop. The indicator LED of power regeneration on the indicator panel is lit with an intensity corresponding to the amount of regeneration energy. Check point Lighting of the indicator LED of the power regeneration unit The power regeneration indicator beyond 150% Lighting of alarm indicator LED... When the LED is not lit although the deceleration operation is made normally, check if setting of the motor section switch is too large. It is natural that the LED is not lit when the regenerated power is small.... When this condition is continued for a long time, the converter may trip due to over-work.... Investigate the cause referring to the information on the protection functions. Note: 1. When the regenerated power is less than 12.5% of the setting motor capacity (see Table 1, page 12), the power regeneration indicator LED is not lit. 2. When the power regeneration converter has operated, the built-in reactor may beep but this is not a fault. 13
6. Maintenance and Inspection 6. Maintenance and Inspection The power regeneration converter is static equipment consisting mainly of semiconductor devices. Sufficient maintenance and inspection must be done to prevent trouble caused by environmental effects, aging and endurance life of the components. 6-1 Suggestions for maintenance and inspection After the power source has been switched off, electrolytic capacitors in the converter are charged by a high voltage for a while. The inspection must be done after the change lamp on the indicator panel has been off and it has been assured by use of a voltmeter or another instrument that a DC voltage between the terminals P/+ and N/- is less than DC30V. 6-2 Inspection items (1) Daily inspection Please check for the following points during operation of the converter. Demonstration of the expected controlling ability Generation of abnormal vibration or sound Overheat or discoloration Cleaning of a filter or ventilator of the enclosure Trouble with the environment surrounding the installation place (2) Periodic inspection Please check the components which can be inspected only after stopping the converter and are required to be inspected periodically. Tightening of the fixing bolts again Corrosion and failure of conductors and insulators Checking and exchanging cooling fan, smoothing capacitor, and relay Trouble with the cooling system (3) How to perform the insulation resistance test When making an insulation resistance test on the power source system, remove the connection cables to the power regeneration converter so that the test voltage is not applied. Perform an insulation resistance test on the power regeneration converter itself with the main circuit terminal block shorted as shown in Fig. 5. Note that the insulation resistance test should not be done on the control circuit. Note: For the conduction test of the controlling circuit, please use a tester (meter) (for low and high ranges), not the insulation resistance tester nor a buzzer. Inverter, Servo R/L1 P/+ P Power source S/L2 N/- N T/L3 Insulation resistance tester Fig. 5 Outline of a megger test 14
7. Problems and countermeasures 7. Problems and countermeasures When a problem unfortunately occurs and the function of the converter is lost, please make its cause clear to take the countermeasures referring to the inspection items describes below. 7-1 Inspection according to the alarm indicator Indicator LED Protection function Cause of the problem Check point Procedures UVT Insufficient voltage Drop of power voltage OCT FIN NGV ERR OCT UVT FIN Lit at the same time OCT flicker Overcurrent Overheat of heat sink Reverse connection of P and N Trouble with control circuit Excess duty Overload Excess regenerated current Overheat of cooling fin Reverse connection of the inverter terminals P and N Trouble generated by the control circuit Excessive regenerative load ratio Excess regenerated current (Current of more than the specified value flew for a long time) Has a large capacity of motor been started? Steep change of the load? Short-circuit and open phase at the power source side? Check for power distortion Has the cooling fan stopped? Has there been an increase in environmental temperature? Reverse connection of terminals P/+ and N- to N and P, respectively? Is there a source nearby generating noise? Is the power regeneration indicator beyond 150% for a long time? Check whether the load is too large. Check the power capacity and the power system. Suppress the fluctuation of the load and check the wiring of the power (see P.8). Exchange cooling fan, lower the environmental temperature. Connect correctly. Investigate the noise source and take the appropriate countermeasures to surpress it. Lower the load, or reconsider the capacity of the converter. Lower the load, or reconsider the capacity of the converter. Note: When any of the above alarm indicator LEDs are lit, the power regeneration converter stops operating. Therefore, the "overcurrent", "overvoltage" or other protective function of the inverter may be activated. When the converter is operated again, reset the converter after the problem cause has been investigated and the cause has been removed. 7-2 Problem phenomena and their countermeasures Check point Countermeasure 1 Wrong wiring Wire correctly 2 Setting of a wrong value for the motor capacity Make sure of the setting value is correct 3 Lighting of the operation lamp for the protection function Reset the converter after remove the cause of the alarm 15
8. Specifications 8. Specifications 8-1 Block diagram R S T U V W To motor (AC reactor for power-factor improvement) power regeneration converter Inverter, Servo Power source NFB R/L1 S/L2 T/L3 P/+ N/- P N CHARGE Jumper R1/L11 S1/L12 Controlling power source POWER Detection of a current Detection of a voltage Phase detection terminals Note : Phase detection terminals are used to prevent overcurrent due to power distortion. (Refer to page 8 ) Jumper R RX S SX T TX R1/L11 S1/L12 Judgement of polarity A B C Output for fault/alarm Reset RES RDY SD Control circuit SE Output for ready signal Overheat of heat sink CPU Indicator panel Grounding 16
8-2 Explanation of the terminals Main circuit Terminal Terminal name Rating Explanation P/+ Input terminals of Terminals for connection with the inverter or servo N/- the converter terminals P, N. R/L1 Input terminals for Terminals for connection of the same input power S/L2 AC power source as that of the inverter or servo. T/L3 R1/L11 S1/L12 Power source terminals for control circuit 3-phase 200V class 200V 50Hz 200 to 230V 60Hz 400V class (Note) 400V 50Hz 400 to 460V 60Hz Connected to the power source terminals R/L1 and S/L2 by a short-circuit plate. When lighting of the trouble indicator lamp is desired, please remove the plate to connect an external power source (see page 7, page 8) Grounding For grounding to the earth Control circuit RES SD A B C RDY SE R RX S SX T TX Input terminal for resetting Common terminal of RES Fault/alarm output terminals Output signal for ready Common terminal of RDY Power phase detection terminals Input resistance 4.7k, during shorting between RES and SD 4 to 6mA DC 1 contact 230V AC 0.3A 30V DC 0.3A Open collector output Allowable load 24V DC 0.1A The remained operation condition of the protection circuit can be released by shorting a circuit between RES and SD for longer than 0.1s Output indicating the operation Normal: closed between B and C, open between A and C Fault : open between B and C, closed between A and C Output signal indicating that the power regeneration converter is ready to operate. Switched Low when the unit is ready. Terminals used to prevent overcurrent due to distortion (refer to page 8) Recommended wire size: 1.25mm 2 to 2mm 2 8-3 Layout of terminals -15K Control circuit terminal block (M4 screw) A B C RDY SE RES SD Power source terminals for control circuit (M4 screw) R1/L11 S1/L12-30K` to 55KC 55K, -H15K` to H55K Control circuit terminal block Phase detection terminals (M4 screw) R RX S SX T TX A B C RDY SE RES SD Power source terminals for control circuit (M4 screw) R1/L11 S1/L12 (Grounding) AC power source input terminals Converter input terminals Phase detection terminals R/L1 S/L2 T/L3 N/- P/+ R RX S SX T TX TB1-2 TB1-1 Jumper (Note) TB1-5 Jumper (Note) TB1-5 (Grounding) AC power source input terminals R/L1 S/L2 T/L3 N/- P/+ TB1-2 Converter input terminals Note: Do not remove the jumpers for other than prevention of overcurrent due to power distortion. Terminal screw size 200V 400V Type TB1-1 TB1-2 TB1-5 -15K -30K -55K -H15K -H30K -H55K M5 M6 M8 M6 M6 M6 M5 M6 M8 M6 M6 M6 M3.5 M3.5 M3.5 M3.5 M3.5 M3.5 Grounding terminal M6 M6 M6 M6 M6 M6 TB1-1 17
8-4 Outline dimensions Power regeneration converter Fixture (removable) 2- C hole H2 Alternative fixing position of fixture Rating name plate Front cover H1 H Indiactor panel window Cooling fan C H3 D1 3.2 W1 D W Exposing portion of heat sink to outside of the enclosure Type W W1 H H1 H2 H3 D D1 C Unit: mm Approximate weight -15K 270 200 450 432 10 8 195 87 10 19kg 200V -30K 340 270 600 582 10 8 195 90 10 31kg -55K 480 410 700 670 15 15 250 135 12 55kg -H15K 340 270 600 582 10 8 195 90 10 31kg 400V -H30K 340 270 600 582 10 8 195 90 10 33kg -H55K 480 410 700 670 15 15 250 135 12 56kg 18
Dimension of panel cutout When the unit is mounted inside an enclosed containing box, machine the mounting section of the containing box to the dimensions shown below for placement of the heat sink of the power regeneration converter outside the box for the purpose of heat dissipation. (W1) 4- D hole Unit: mm Panel cutout Type Wa Hb D -15K 260 412 10 (H1) Hb±2 200V -30K 330 562 10-55K 470 642 12 -H15K 330 562 10 400V -H30K 330 562 10 Wa±2 -H55K 470 642 12 19
8-5 Standard specifications Type - 15K 30K 55K H15K H30K H55K Rated input AC power source (Note 3) Allowable fluctuation of AC voltage Capacity of input power source (kva) (Note 1) 200V class 3 phase 200V 50Hz, 200 to 230V 60Hz 180 to 220V 50Hz, 180 to 253V 60Hz 400V class 3 phase 400V 50Hz, 400 to 460V 60Hz 360 to 440V 50Hz, 360 to 506V 60Hz 28 52 100 28 52 100 Rated current (A) (Note 2) 31 63 91 16 31 58 Applicable motor capacity (servo) Braking torque %ED Input and output signals Setting function Protection function Indication Environmental temperature Braking torque and %ED depend on the motor capacity applied. See page 21 and 22. The torque depends on the applied motor capacity and time rating (short time, continuous). See page 21 and 22 for details. The time rating depends on the applied motor capacity and the braking torque. See page 21 and 22 for details. Input Resetting signal Signal Output Signal Signal for standing by (open collector), alarm signal (1 contact) Setting an usable motor capacity (setting dial) Insufficient voltage, overcurrent, overheat of fin, reverse connection of P and N, over-duty, control problem Indication of the regenerated power condition by a bar type LED, indication of the alarm content by a LED -10 to +50 C (non-freezing) Environment Environmental humidity Less than 90% RH (non-condensing) Storage temperature -20 to +65 C Atmosphere Altitude, vibration Protection construction (JEM 1030) Indoors, free from corrosive gas, oil mist, inflammable gas, dust etc. Less than 1000m above sea level, acceleration of less than 5.9 m/s 2 (according to JIS C 0040) Open type (IP00) Cooling method forced-air cooling Note 1: The indicated value is the same as the power source capacity of the same capacity of inverter. When the power regeneration converter and the inverter are combined, make preparation so that the power source capacity is larger than this value. Note 2: Current which flows in the main circuit DC bus (terminals P/+, N/-). Note 3: The 400V class cannot be used with the AC servo. 20
8-6 Selection of peripheral devices 200V 400V Used power source voltage and type Usable motor capacity (kw) No-fuse breaker (NFB) Magnetic contactor (MC) Cable size (AWG) R/L1, S/L2, T/L3-15K 7.5 to 15 225AF 125A S-N65 5 5-30K 15 to 30 225AF 225A S-N125 5 5-55K 30 to 55 400AF 400A S-N220 4 4 -H15K 7.5 to 15 100AF 60A S-N25 5 5 -H30K 15 to 30 225AF 125A S-N65 5 5 -H55K 30 to 55 225AF 200A S-N100 5 5 Use cable of equal or greater cross sectional area than the value indicated above. Set the internal dial according to the motor capacity. P/+, N/- Heat generated by the power regeneration converter (Reference values) 200V Applicable power source voltage and type Heat generation (W) -15K 500-30K 1050 Note: Indicates the heat generated at continuous rating (braking torque 75%). -55K 1850 -H15K 500 400V -H30K 1000 -H55K 1800 8-7 Selection guide [Application to an inverter] 1 Select a power regeneration unit suitable for the motor capacity. 2 Even if only the inverter capacity is increased by more than one rank, the braking torque and %ED are given as the values indicated in the following table. %ED for 150% braking torque, 30-second short-duration rating Motor capacity 7.5kW 11kW 15kW 18.5kW 22kW 30kW 37kW 45kW 55kW Inverter 200V 7.5K 11K 15K 22K 22K 30K 37K 45K 55K 400V 7.5K 15K 15K 22K 22K 37K 37K 55K 55K 200V 400V -15K 45 45 25-30K %ED 45 30 25 25-55K 45 35 25 25 -H15K 45 45 25 -H30K %ED 45 45 45 25 -H55K 45 45 45 25 21
400V 200V Braking torque (%) for 50%ED, short-duration rating Motor capacity 7.5kW 11kW 15kW 18.5kW 22kW 30kW 37kW 45kW 55kW 200V 7.5K 11K 15K 22K 22K 30K 37K 45K 55K Inverter 400V 7.5K 15K 15K 22K 22K 37K 37K 55K 55K -15K Braking 140 140 100 80 70-30K torque 140 110 100 100 80 70-55K (%) 140 120 100 100 -H15K Braking 140 140 100 80 70 -H30K torque 140 140 140 100 80 70 -H55K (%) 140 140 140 100 Example 1 Travelling operation Rotation rate tc tb Time 200V 400V Braking torque for continuous rating (%) Motor capacity 7.5kW 11kW 15kW 18.5kW 22kW 30kW 37kW 45kW 55kW Inverter 200V 7.5K 11K 15K 22K 22K 30K 37K 45K 55K 400V 7.5K 15K 15K 22K 22K 37K 37K 55K 55K -15K Braking 100 100 75 55 50-30K torque 100 80 75 75 55 50-55K (%) 100 85 75 75 -H15K Braking 100 100 75 55 50 -H30K torque 100 100 100 75 55 50 -H55K (%) 100 100 100 75 Rotation rate Example 2 Lifting operation t1 tc t2 t3 t4 tb=t1+t2+t3+t4 Time ratio of power regeneration load %ED = (Operation frequency) tb < 30s (continuous operation time) tb tc Time 100 [Application to an AC servo] The power regeneration converter can be used with the MELSERVO-H series 3.5kW (MR-H350 ) to 22kW (MR-H22K ) AC servo. Always use the 200V class power regeneration converter with the AC servo. The 400V class power regeneration converter cannot be used. The following tables indicate the characteristics for combinations of the servo amplifiers and power regeneration converter. Braking torque at continuous rating Servo amplifier type MR-H350 MR-H500 MR-H700 MR-H11K MR-H15K MR-H22K -15K Braking 300 225 150 100 75 50-30K torque 200 150 100-55K (%) 185 Maximum braking torque Servo amplifier type MR-H350 MR-H500 MR-H700 MR-H11K MR-H15K MR-H22K -15K Braking 300 300 300 200 150 100-30K torque 300 300 200-55K (%) 300 22
REVISIONS * The manual number is given on the bottom left of the back cover. Print Date *Manual Number Revision Jul., 1991 IB(NA)-66330-A First edition Apr., 2000 IB(NA)-66330-B Additions SAFETY INSTRUCTIONS Modifications Wiring method Terminal block addition Mar., 2001 IB(NA)-66330-C Partial addition To prevent overcurrent due to distortion